Electrical terminal



July 17, 1956 L. A. CLOUTIER ELECTRICAL TERMINAL 2 Sheets-Sheet 1 FiledAug. 6, 1952 n fix nu A 0 02 A .Zuca'en July 17, 1956 Filed Aug. 6, 1952A. CLOUTIER 2,755,453

ELECTRICAL TERMINAL- 2 Sheets-Sheet 2 1 g. 9. fig. 10.

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United States Patent ELECTRICAL TERMINAL Lucien A. Cloutier, Attleboro,Mass, assignor to Metals & Controls Corporation, Attleboro, Mass, :1corporation of Massachusetts Application August 6, 1952, Serial No.302,940

Claims. (Cl. 339-220) the class described which can be firmly fastenedinto a terminal block by means of a simple and novel crimping operation; the provision of a terminal of the class described which, afterbeing crimped into a terminal block resiliently retains its tightnesstherein; and the provision of an electrical terminal having expansibleportions therein for fastening purposes. Other objects will be in partobvious and in part pointed out hereinafter.

The invention accordingly comprises the elements and combinations ofelements, features of construction, and arrangements of parts which willbe exemplified in the structures hereinafter described, and the scope ofthe application of which will be indicated in the following claims.

In the accompanying drawings, in which several of various possibleembodiments of the invention are illustrated:

Fig. 1 is an elevation of one embodiment of this invention;

Fig. 2 is a side view of Fig. 1;

Fig. 3 is a view of the Fig. 2 device, but showing the terminal afteranother operation has been performed on it to make a second embodimentof this invention;

Fig. 4 is an isometric view of the terminal of Fig. 3;

Fig. 5 is a cross sectional view of the Fig. 4 terminal shown mounted ina terminal block;

Figs. 6 and 7 are plan views of sections of terminal blocks illustratingshapes of mounting holes therein for the Figs. 2 and 3 terminals;

Fig. 8 is an elevation of another embodiment of the invention;

Fig. 9 is a side view of the Fig. 8 embodiment;

Fig. 10 is an elevation, partly in section, showing the Fig. 8 terminalmounted in a terminal block;

Fig. 11 is a side view of the mounting of Fig. 10;

Fig. 11 is a side view of the mounting of Fig. 10; and

Figs. 12 and l3 are plan views showing alternative embodiments of thisinvention.

In the manufacture of electrical switches, for example, use is oftentimes made of terminals or electrical contact structures which aremounted in an insulating terminal block or some other part of the switchstructure, by means of the terminal or contact structure being insertedin a hole through the terminal block and thereafter being crimped tohold the device securely in place. (Hereinafter, the word terminal" willbe used to denote terminals per se, or contact structures, orcombination terminal and contacts.) Due to manufacturing tolerances, itis relatively expensive to have the hole (into which the terminal is tobe inserted) the exact size and shape of the terminal, with the resultthat the strength of the crimps formed by the crimping operation isrelied upon to keep the terminal from having free play in the hole. Withmany switches, this problem of tightness of the terminal is not seriousbecause in those cases the terminal merely acts as a device to whichelectric wires, etc. are to be soldered. How ever, in other types ofelectrical switches, and particularly in switches of the kind shown inthe Bolesky Patent No. 2,199,387 free play (or looseness) of theterminal is objectionable. This is because of the fact that in such aconstruction, any loose play of the terminal may result in a change inthe calibration of the thermostatic element, since the face of theterminal acts as a stationary electrical contact.

It is the general purpose, therefore, of this invention to provide aterminal which may be mounted in a hole in the terminal block in a firmand secure way with a minimum of loose play, and which uses a minimum ofexpensive contact material.

Referring now to the drawings, there is shown in Figs. 1 and 2,elevation and side views, respectively, of one embodiment of thisinvention. In this instance, indicated generally by numeral 1, is aterminal made of a layer of silver 2 bonded to a base metal layer 3. Asshown, the terminal consists of a broad shank portion 4, a narrow shankportion 5, and a bent-over head 6, the head to act as an electricalcontact. Terminal 1 is preferably blanked from sheet stock, the sheetstock itself comprising a layer of silver bonded to a layer of basemetal, by conventional blanking dies,

Indicated by numeral 7 is a slit (or narrow slot) sheared or piercedcompletely through the narrow shank portion 5 and positioned entirelywithin the shank as shown. The terminal of Figs. 1 and 2 may be used inthis form, if desired, but there will now be described a second embodiment (Fig. 3) which results from another operation being performed onthe Fig. 1 terminal. The Fig. 3 device is preferred over the Fig. 1device for reasons which will be given below.

In Fig. 3 is shown the Fig. 1 terminal with an additiona] operationperformed on it, to bend outwardly and away from each other, as shown,the legs 8 and 9 produced by the slit 7. In this instance the bend shownis elliptical, but it could be circular or parabolic, etc., or it couldbe in the form of a triangular bend.

Fig. 4 shows an isometric view of the Fig. 3 terminal illustrating ingreater detail the respective arrangement of parts.

The terminals shown in Figs. 1, 2 and 3 can be manufactured by simpleblanking and forming operations from the sheet stock referred to above,using progressive dies on high speed blanking and forming machinery.This leads to economy of manufacture.

As to the method of using the Figs. 1, 2 and 3 terminals, there areshown in Figs. 6 and 7 plan views of sections of terminal blocks havingmounting holes provided therein. Referring first to Fig. 6, the terminalblock 10 has provided therein a rectangularly shaped mounting hole 11which extends through the terminal block. This hole is for use with theterminal shown in Figs. 1 and 2, and the shape and dimensions of hole 11are such as to contain the broad shank portion 4 with as snug a fit asmanufacturing tolerances allow.

Referring now to Fig. 7, the terminal block 12 has therein the mountinghole 13 which is shown as having a rectangular center section 14 and thetwo end sections 15 and 16, these end sections being approximately ofthe same size. Hole 13 is to be used with the Fig. 3 terminal, and endsections 15 and 16 are provided to permit the curved legs 8 and 9,respectively, to pass through the terminal block.

Referring now to Fig. 5, there is shown the terminal block 12 with theFig. 3 terminal mounted therein. The terminal is mounted in this way:First the terminal is in serted in hole 13 so that the bent-ovcr contacthead 6 rests snugly against the surface 17 of terminal block 12. Thenwhile head 6 is held against surface E7, the narrow shank portion ispushed toward head 6. Because of the precurvature of legs 8 and 9. theselegs will bend further outwardly with the result that the carved outlegs (now indicated by numerals I3 and 19) became crimped bent portionswhich hold the terminal fittliit'ciy in the terminal block 12. Also, ifthe end 26) of siot 7 nearest head 6 is so positioned that it lieswithin the block, then the outwardly bending legs 8 and 9 will fulcrumagainst the edge of the hole in surface 21 of the terminal block to tendto draw the terminal tightly into the hole.

The terminal shown in Figs. 1 and 2 is to be used with the hole 11 shownin Fig. 6. In this case, there is no need of the side extensions 15 and16, because legs 8 and 9 of the terminal are not pre-formed as in Fig.3. After terminal 1 is inserted in hole 11, then it will be necessary tobend legs 8 and 9 sideways away from each other to start the crimpingoperation. This sideways EHO- tion may be continued to impart thecomplete crimp shown in Fig. 5, but it is preferable to combine theinitial sideways bending with lengthwise pressure on the end of narrowshank portion 5 to assist in the crimping.

Referring now to Fig. 8, there is shown another cmbodiment of thisinvention, wherein the shank of the ter minal again is formed with twointegral legs which will be expanded outwardly in order to fasten theterminal into its terminal block. In this instance, the terminal againhas the wide shank portion 24, the narrow shank portion 25, and thebent-over head 26. It will be noticed again that the terminal in thisinstance is made of laminated material, as was the terminal shown inFigs. i. 2 and 3. (It is obvious, of course, that instead of being madeof laminated material, this terminal as well as the prior terminals canbe made of non-laminated electrical contact material such as silver,gold, platinum, or cop per, etc.) In this instance, a triangularlyshaped hole 27 is pierced through the shank of the terminal, and theshank is notched as indicated at 28 to provide the leg portions 29 and30.

Referring to Figs. 10 and ll, there is shown a cross sectional view ofthe terminal of Fig. 8 mounted in a terminal block. In this case, afterthe terminal has been inserted in a hole such as that shown by numeral Hin Fig. 6, the head 26 again is held firmly against the surface 31 ofthe terminal block 32, and while being htrhl. force is exerted againstthe end of narrow section 35' to push it toward the head 26. This bendsthe legs 29 and 30 outwardly away from each other as shown in Fig. 10.In this case, the bottom of the hole I] is provide: with the roundedshoulders 33, the purpose of which it to act as fulcrum points againstwhich the legs 29 and 30 may bear. It is seen that the bending forceapplied to arms 29 and 30 is applied approximately at the bending points34 and 3S and that there is a component thereof perpendicular to thesurface of the terminal block. This component is on one side of thefulcrum points 33, and the resisting force is the force that the head 26is er.- erting against surface 31 through the medium of the wide shankportion 24. The results, therefore. of this fulcrum action is to drawand maintain head 26 firmly against surface 3!.

Shown in Figs. 12 and 13 are further modifications of the Fig. 8terminal, the legs 36 and 37 of the Fig. 12 embodiment being formed bypiercing a circular hole in the narrow section of the shank; and thelegs 38 and 39 of the Fig. l3 embodiment being formed by piercing ahexagonal hole in the narrow section of the shank.

Other forms of piercing a leg shape will suggest themselves to onereading this disclosure. However, it will be noted that in all theembodiments shown herein, the

basic principle is that of providing two or more leg sections integrallyformed fro-m the shank of the terminal, these leg portions beingexpanded outwardly to act as fastening portions to hold the terminal inthe terminal block, by forcing the narrow portion of the terminal towardthe head to cause this outward bending. (For example, three legs can beprovided in the Fig. 1 or 3 types, with the center leg being bent in onedirection and the other two being bent away from the center leg.) Inspeaking thus of forcing the narrow section of the terminal toward thehead to cause the bending, it is contemplated that in some instances theforce may be applied sidewise against the legs to cause that sidewisebending, with the result that the narrow section of the terminal shankmoves toward the head. However, it is preferable for ease and economy ofinsertion, to cause the crimping action by applying the force to the endof the narrow shank to cause the sidewise bending and crimping.

In view of the above, it will be seen that the several objects of theinvention are achieved and other advantageous results attained.

As many changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings, shall be interpreted as illustrative and not in a. limitingsense.

I claim:

I. A terminal for an electric device, comprising a flat sheet metalshank and a flat sheet metal head integrally attached to said shank;said shank being provided with at least one hole therein to provideinner walls; said shank having its outer edges notched, the boundary ofsaid notches defining, together with said inner walls, a pair of legsintegral with said shank, attached thereto at both ends, and inclined atan angle to the length thereof; at least a portion of said legs beingadapted to be bent away from each other.

2. A terminal for an electric device, comprising a head and a shank;said shank having for part of its length a wide portion and for the restof its length a narrow portion; the narrow portion of said shank beingparted at approximately its center to provide two legs; each of saidlegs lying in the plane of the shank and being joined at one end to saidwide portion and at the other end to said narrow portion; and said legsbeing outwardly inclined at an angle to the length of the shank wherebysaid legs are adapted to be bent further apart by motion of the narrowportion of the shank toward the wide part of the shank.

3. A terminal for an electric device, comprising a fiat sheet metalshank and a flat sheet metal head integrally attached to the shank, saidshank having two leg portions, said leg portions being integral withsaid shank and each of said leg portions being joined at both of itsends to said shank; said leg portions extending outwardly away from eachother in opposite directions in the plane of the face of said shank, andat least a portion of each of said legs being adapted to be bentoutwardly away from the other.

4. A terminal for an electric device, comprising a flat sheet metalshank and a flat sheet metal head integrally attached to the shank, saidshank being provided with a polygonal shaped hole therein, to form legsintegral with said shank and attached thereto at both ends, said legsbeing initially at an angle to each other in the plane of said shank,and at least a portion of each of said legs being thus adapted to bebent outwardly away from each other by forcing the ends of said shanktowards each other.

5. In combination, a terminal block and a terminal, said terminalincluding two surfaces and providing a hole therein extending from oneof said surfaces to the other, said terminal comprising a head and ashank, said shank being formed of sheet metal and comprising a flatportion, two legs and another portion, said flat portion being snuglyreceived in said hole, one end of said flat portion being integral withone end 0 each of said legs, the opposite end of each of said legs beingintegral with said other portion of said shank, said head being disposedagainst one of said surfaces of the terminal block and each of said legsextending outwardly away from the other and lying tightly against theother surface of said terminal block to maintain said head firmlyagainst said one surface.

References Cited in the file of this patent UNITED STATES PATENTS1,143,457 Spill June 15, 1915 6 Russell Dec. 27, 1927 McCormack June 5,1934 Norwood July 2, 1935 Hall May 5, 1936 Gilbert July 7, 1936 GardnerDec. 12, 1939 Coffin Dec. 9, 1941 Chirelstein Aug. 4, 1942

